Support For Catalina Cylinders Clientele

In CGA pamphlet C-6.1, Standards for Visual Inspection of High Pressure Aluminum Compressed Gas Cylinders, it states in section 4.2 that cuts or digs are acceptable to the following limits:

1. 1. Unknown wall thickness, maximum dig = .031″ deep

1. 1. Known wall thickness, maximum dig = 15% of minimum design wall thickness.a) A dig in the sidewall could be:
      .471″ (min side wall) x .15% = .071″ deep

      b) A dig in the center of the base (the thinnest part of the base) could be:
      .735 (min base) x .15% = .110″ deep

      c) A dig in the radius and footring at the bottom of the cylinder could be:
      .110″ deep + .04″ footring height) = * .150″ deep
      * This dig cannot extend up into the sidewall.

1. The length of the dig must be less than 6.0″

Catalina Cylinders recommends the following care and maintenance of SCUBA cylinder to minimize corrosion.

Daily Corrosion Maintenance

Never fill a cylinder with wet or contaminated air.

SCUBA cylinders must be thoroughly rinsed off with fresh water after each dive – especially when diving in saltwater. It takes time to dissolve salts and chemicals so just wetting the cylinder shall not be enough to remove dried salt and mineral deposits. While rinsing off the cylinder, wipe around every feature, accessory, and area where paint has been removed. When rinsing is completed, dry the cylinder. In areas where accessories are attached to the cylinder it is recommended to dry the cylinder with a towel.

Minimize the type of handling, storage and racking of a cylinder that will produce continuous isolated wear to the paint on the cylinder. If a cylinder is fitted in a pack, make sure the cylinder does not move in a way to cause scarring to the paint. If the cylinder is stored in a storage rack, make sure the cylinder is cushioned from hard impact or constant rubbing.

Periodic Corrosion Maintenance

For SCUBA cylinders filled daily, all accessories must be removed from the cylinder and the cylinder be thoroughly washed and dried once a month. The accessories should be washed and dried too. It is recommended that the valve of the cylinder is removed at least every six months and the cylinder is inspected internally to ensure that the cylinder is dry inside. If the cylinder is wet inside, clean, and thoroughly rinse and dry the inside of the cylinder before returning the cylinder to usage. Never fill a cylinder with wet or contaminated air. This is in addition to the standard daily cleaning.

It is recommended that accessories made of dissimilar metals be insulated from being in direct contact with the cylinder. For accessories made of dissimilar metals that are in contact with the scuba cylinder, remove the accessories and then wash and dry the cylinder and accessories twice a month.

Long Term Storage Corrosion Maintenance

For SCUBA cylinders that will not be used for a long period of time, a month or longer, remove all accessories from the cylinder. Thoroughly wash and dry the cylinder inside and outside. Wash and dry the accessories too. Inspect the valve for corrosion or missing chrome plating. If the valve is free of corrosion and the chrome platting is intact, re-install the valve with a little Dow III lubricant on the threads and with a new o-ring. Catalina Cylinders recommends using a 214 o-ring with a 90 shore. Store the washed, dried and valved cylinder in the upright position in a cool, dry and salt-free environment. If the cylinder cannot be stored in a salt-free environment it is recommended that the cylinder be stored without the accessories attached. Store the cylinder with a slight positive pressure, approximately 20 – 100psi.

Catalina Cylinders recommends the following care and maintenance of SCUBA cylinder to minimize corrosion.

Daily Corrosion Maintenance

Never fill a cylinder with wet or contaminated air.

SCUBA cylinders must be thoroughly rinsed off with fresh water after each dive – especially when diving in saltwater. It takes time to dissolve salts and chemicals so just wetting the cylinder shall not be enough to remove dried salt and mineral deposits. While rinsing off the cylinder, wipe around every feature, accessory, and area where paint has been removed. When rinsing is completed, dry the cylinder. In areas where accessories are attached to the cylinder it is recommended to dry the cylinder with a towel.

Minimize the type of handling, storage and racking of a cylinder that will produce continuous isolated wear to the paint on the cylinder. If a cylinder is fitted in a pack, make sure the cylinder does not move in a way to cause scarring to the paint. If the cylinder is stored in a storage rack, make sure the cylinder is cushioned from hard impact or constant rubbing.

Periodic Corrosion Maintenance

For SCUBA cylinders filled daily, all accessories must be removed from the cylinder and the cylinder be thoroughly washed and dried once a month. The accessories should be washed and dried too. It is recommended that the valve of the cylinder is removed at least every six months and the cylinder is inspected internally to ensure that the cylinder is dry inside. If the cylinder is wet inside, clean, and thoroughly rinse and dry the inside of the cylinder before returning the cylinder to usage. Never fill a cylinder with wet or contaminated air. This is in addition to the standard daily cleaning.

It is recommended that accessories made of dissimilar metals be insulated from being in direct contact with the cylinder. For accessories made of dissimilar metals that are in contact with the scuba cylinder, remove the accessories and then wash and dry the cylinder and accessories twice a month.

Long Term Storage Corrosion Maintenance

For SCUBA cylinders that will not be used for a long period of time, a month or longer, remove all accessories from the cylinder. Thoroughly wash and dry the cylinder inside and outside. Wash and dry the accessories too. Inspect the valve for corrosion or missing chrome plating. If the valve is free of corrosion and the chrome platting is intact, re-install the valve with a little Dow III lubricant on the threads and with a new o-ring. Catalina Cylinders recommends using a 214 o-ring with a 90 shore. Store the washed, dried and valved cylinder in the upright position in a cool, dry and salt-free environment. If the cylinder cannot be stored in a salt-free environment it is recommended that the cylinder be stored without the accessories attached. Store the cylinder with a slight positive pressure, approximately 20 – 100psi.

The U.S. Department of Transportation (DOT) and Canada’s Transport Canada (TC) require that cylinders made in compliance to their specifications be marked on the crown with certain information. Over the years the format used by Catalina Cylinders and Catalina East Division to display these markings has changed. Shown below is an example of the current crown markings stamped on the standard S80 (80 cu ft, 3000 psi) SCUBA cylinders manufactured at Catalina Cylinders, Garden Grove, CA. Under the example of the crown marking is a list of each of the specific crown markings followed by a brief explanation of that marking. The descriptions of the markings are the same regardless of the different stamping formats used over the years.
Example of the crown marking on an S80 SCUBA Cylinder:
DOT-3AL3000..ASXXXXXXX M4002 07C08 CATALINA S80 SP12 TC-3ALM207

DOT-3AL The U.S. regulatory authority, the Department of Transportation (DOT), and specification, 3AL, to which the cylinder is manufactured in compliance (required mark).

3000 The service pressure, in pounds per square inch (psi), of the cylinder (required mark).

ASXXXXXXX The serial number of the cylinder. For Catalina Cylinders, the serial number prefix of “AS” is specific to the S80 (80 cu ft, 3000 psi) SCUBA cylinders followed by a six digit number.

M4002 The M-number or Manufacturers Number issued by the DOT to the manufacturer, Catalina Cylinders (required mark). This mark is recognized by TC

07C08 The original hydrostatic test date of the cylinder, month followed by year, performed at the time of manufacture of the cylinder. The “*” represents the symbol of the Independent Inspection Agency (IIA) performing the inspection of and certifying the acceptance of the cylinder at the time of manufacture (required mark).

CATALINA The name of the manufacturer of the cylinder.

S80 The cylinder identifier. It identifies the market, “S” for SCUBA, and capacity, “80” for a capacity of 80cuft charge, of the cylinder.

SP12 The cylinder outlet thread designation as specified in CGA TB-16.

TC-3ALM The Canadian regulatory authority, Transport Canada (TC), and specification, 3ALM, to which the cylinder is manufactured in compliance (required mark).

207 The service pressure of the cylinder expressed in metric units, bars (required mark).

Catalina Cylinder Corporation manufactured high-pressure aluminum cylinders until December of 1991. In the crown forming operation of the manufacturing process, flame heat was used to heat the end of the product prior to forming the crown of the cylinder. After the product was heated, the product was forced from the base end into a die to form the crown end. Sometimes the flame heat was insufficient to properly allow the product to flow and form the crown end of the cylinder without causing uniform distortion of the lower sidewall of the cylinder. This distortion would appear as a uniform bulging of the cylinder’s lower sidewall starting about two inches up from the base of the cylinder. The distortion would not be localized but would be uniform around the cylinder. In addition, the distortion would only be located in the lower sidewall of the cylinder and nowhere else.

If you have a Catalina Cylinder Corporation cylinder manufactured in the late 1980’s that has a uniform bulge all the way around the lower sidewall of the cylinder just above the base of the cylinder, the manufacturing process most likely caused it. Hydrostatically test the cylinder and if the cylinder passes hydrostatic test, then the cylinder is acceptable for further service.

If you have a cylinder that has a localized bulge (not bow) in the sidewall of the cylinder, then the cylinder should be condemned and taken out of service.

At Catalina Cylinders, the minimum number of threads required is based on information from Fed Standard H-28. Fed Standard H-28 is referenced directly in 49 CFR 178.46; DOT-3AL. The minimum number of threads required in a SCUBA cylinder with �-14 NGS threads varies depending on the service pressure. Listed below are the minimum number of threads required for aluminum SCUBA cylinders with �-14 NGS threads at different service pressures as calculated by Catalina Cylinders.

Note: The minimum number of threads is rounded up to the next complete (whole) thread.

PLEASE NOTE: This document only applies to Catalina Cylinders, new and used, SCUBA cylinders and in no way is meant to apply to the SCUBA cylinders manufactured by different entities.

Prior to June 2006, Catalina Cylinders SCUBA cylinders, as-manufactured, were not specifically cleaned for oxygen service and therefore are under no circumstances to be charged with oxygen enriched air, air containing oxygen concentrations in excess of 23.5%, unless the SCUBA cylinders have been specifically cleaned for oxygen service by trained personnel and labeled as such.

As of June 2006 all 3000psi service pressure, or less, Catalina Cylinders SCUBA cylinders, as-manufactured, have been specifically cleaned for oxygen service and therefore can be charged with oxygen enriched air immediately after purchase.

To charge a Catalina Cylinders SCUBA cylinder with oxygen enriched air, the following items must be verified before charging:

1. 1. The cylinder is currently clean as if for oxygen service. It should be a new 3000psi or less Catalina Cylinders SCUBA cylinder or a used Catalina Cylinders SCUBA cylinder that has a cleaned for oxygen service and a label affixed stating as such.

1. 1. All accessories and components which will come in contact with the oxygen enriched air charge have been manufactured cleaned for oxygen service or have been cleaned and certified as clean for oxygen service by properly trained personnel.

1. 1. All lubricants used on Catalina Cylinders SCUBA cylinders, all accessories and components which come in contact with the oxygen enriched air charge are compatible with high pressure oxygen usage and aluminum.

1. 1. The o-rings and other non-metallic materials which come in contact with the oxygen enriched air charge are compatible with high pressure oxygen usage.

1. All other items and materials that may come in contact with oxygen enriched air during the charging, use and/or storage of the Catalina Cylinders SCUBA cylinder and its components and accessories which have been cleaned for oxygen service, have been cleaned for oxygen service.

Warnings

1. 1. Failure to verify the above items have been addressed before charging a SCUBA cylinder with oxygen enriched air may lead to a catastrophic event that can cause property damage, serious injury or even death.

1. The U.S DOT has interpreted its regulations stating that DOT-3AL (aluminum) SCUBA cannot be charged with oxygen enriched air to a service pressure greater than 3000psi. Thus, Catalina Cylinders 3300psi compact SCUBA cylinders cannot be charged with oxygen enriched air as mandated by the DOT. For more information on this matter please contact Catalina Cylinders.

The retest pressure is 5250psi for all SP 12079 steel SCUBA cylinders.

All Department of Transportation (DOT) Special Permit (SP) 12079 steel SCUBA cylinders must be requalified at a retest pressure equal to 3/2 (1.5) times the design service pressure of the cylinder. This may be confusing to some who are in possession of SP 12079 steel SCUBA cylinders marked with a service pressure of 3442psi, “DOT-SP12079-3442”. Following is an explanation of how cylinders marked with the same special permit number, “SP 12079”, and marked with two different service pressures, “3500” and “3442” are to be requalified at the same retest pressure, “5250psi”.

The United States (US) DOT requires that all specification cylinders be periodically requalified as identified in 49 CFR section 180. In 49 CFR 180.205 (c); Periodic Requalification of Cylinders it states,” Each cylinder bearing a DOT special permit number must be requalified and marked in conformance with this section and the terms of the applicable special permit (SP 12079).” To perform requalification in conformance with the terms of the special permit, it is interpreted that a copy of the special permit is on hand or can be accessed electronically. Copies of special permits can be attained by accessing the US DOT PHMSA webpage.

All steel SCUBA cylinders marked with DOT-SP 12079 have been designed with a service pressure of 3,500psi as noted on page 4 of the SP 12079 regardless of when they were manufactured. The original steel SCUBA cylinders marked against this specification were marked with “DOT-E12079-3500”. The next generation of these steel SCUBA cylinders were marked slightly differently, “DOT-SP12079-3500” due to a change by the DOT in identifying these cylinders now as special permit (SP) cylinders replacing the exemption (E) cylinder identification. Even though all E or SP 12079 steel SCUBA cylinders have been designed with a service pressure of 3500psi, cylinders manufactured since late 2007 have been marked with a lower service pressure of 3442psi, “DOT-SP12079-3442”. These cylinders are marked with the lower service pressure of 3442psi so that standard SCUBA valves can be used on these cylinders. Cylinders marked with a service pressure of 3442psi must not be used in service at a pressure greater than 3442psi.

As stated earlier, special permit cylinders must be requalified in accordance with the requirements of the DOT regulation and the special permit. In SP 12079 section 8; Special Provisions paragraph (f) it states, “Each cylinder must be requalified for use every 5 years in accordance with 180.205 as prescribed for DOT specification 3AA cylinders except the minimum retest pressure must be 3/2 (1.5) times the service pressure.”

In conclusion, since the design service pressure of all SP 12079 cylinders is 3500psi, regardless if they are marked at 3500psi or 3442psi, the requalification (retest) pressure must be 5250psi.

US / Canadian Cylinders
Note: The current serial number prefix system was implemented in 1993. Cylinders manufactured prior to September 1993 did not have serial number prefixes specific to the different cylinder types. The serial number prefixes of these cylinders began with “A” through “D”. The current serial number prefix system is as follows:

3000 psi SCUBA Cylinders

3300 psi SCUBA Cylinders

All scuba cylinders should be subjected to an annual visual inspection under normal use. A cylinder subjected to an average of one fill a day or more is considered a cylinder subjected to high use. A cylinder subjected to high use should be visually inspected, both externally and internally, a minimum of every six months. Annual visual inspection includes the inspection of the threads and neck of a cylinder. Thread and neck inspection can only be performed with the valve removed from the cylinder and all foreign material (i.e. dirt, Corrosion, etc.) removed from the o-ring gland and threads. Thread and neck inspection is performed visually with the aid of a light source and a 2X mirror or other acceptable 2X method.

Catalina Cylinders recommends that the items defined below be included in the thread and neck inspection of Catalina Cylinders’ scuba cylinders subjected to annual visual inspection. The rejection criteria for each item are listed under that item.

Minimum Number of Threads

The minimum numbers of complete threads required in Catalina Scuba Cylinders’ cylinders are:

The minimum number of complete threads is counted from the top thread down. The minimum number of complete threads cannot be interrupted by any discontinuities (i.e. valleys, folds, corrosion, or damage).

Rejection criteria:

Cylinders with less than the minimum number of complete threads required for the above noted service pressures are unacceptable.

Replacement Policy:

Catalina Cylinders Return Authorization Policy covers cylinders manufactured with less than the minimum number of complete threads required.

Valley

A valley is a lack of metal condition at the bottom of the threads. A valley is created during the crown forming operation. A valley has an inverted “U” appearance in the bottom of the threads. The contour of a valley is generously rounded.

Rejection Criteria:

A valley is unacceptable if:

• it interrupts the required minimum number of complete threads and
• it creates a thread imbalance of 6 threads or more

An unacceptable valley is a manufacturing related defect covered by Catalina Cylinders Return Authorization Policy.

Thread Imbalance

A thread imbalance is the count of partial threads in a cylinder. A thread imbalance is the difference between the number of complete threads and the number of total threads (complete threads and partial threads) in a cylinder.

Rejection Criteria:

A thread imbalance is unacceptable if:

• It interrupts the required minimum number of threads in a cylinder, or
• It measures an imbalance of 6 threads or more

Replacement Policy:

An unacceptable thread imbalance is a manufacturing related defect covered by Catalina Cylinders Return Authorization Policy.

Folds

A fold is a condition at the bottom of the threads or in the shoulder of a cylinder. A fold is created during the crown forming operation and is actually the metal folding over on itself during the forming operation. A fold is a static condition – not propagating or growing in magnitude. A fold has an inverted “V” appearance in the bottom of the threads. Typically a fold will have a linear indication running down the deepest part of the fold. The contour of a fold is sharp at its deepest point. A fold is similar in appearance to and often mistaken for a crack, a dynamic condition, which can occur in 6351 alloy cylinders (an alloy never used to manufacture Scuba Tanks by Catalina Cylinders).

Rejection Criteria: (in accordance with CGA 6.1 2013-6^th edition Paragraph 5.9.2

A fold is unacceptable if:

• it interrupts the required minimum number of complete threads, or
• it interrupts two complete threads, or
• it causes loss of contents of the cylinder

Replacement Policy:

An unacceptable fold is a manufacturing related defect covered by Catalina Cylinders Return Authorization Policy.

Corrosion

Corrosion can occur in the threads of a cylinder if moisture, possibly by charging the cylinder with wet air, enters the cylinder. A scuba valve that is not fully chrome plated may accelerate the corrosion process in the thread section of a cylinder. Corrosion can occur on the top surface of the cylinder and in the o-ring gland of the cylinder.

Rejection Criteria:

Corrosion is unacceptable if:

• it interrupts the required minimum number of complete threads, or
• it interrupts two complete threads, or
• it causes loss of contents of the cylinder

Replacement Policy:

Corrosion is not a manufacturing related condition and is not covered by Catalina Cylinders Return Authorization Policy.

Rejection Criteria:

Any linear indication that interrupts two complete threads is reason for reject (not condemned). Cylinder reject conditions should have the reject condition visually verified before condemning the cylinder.

Replacement Policy:

Corrosion pits, an acceptable valley, and 1 thread fold are not covered by Catalina Cylinders Return Authorization Policy.

Cylinders that exhibit unacceptable manufacturing conditions (i.e. folds, or lack of complete threads) that extend two threads are covered by Catalina Cylinders Return Authorization Policy.

Tool Stop Marks

Tool Stop Marks appears as linear indications in the threads of a cylinder. The tool that cuts the threads into a cylinder creates tool stop marks. A tool stop mark is a slight build-up of metal at the location where the thread cutting tool stops, hence the name tool stop mark. Tool stop marks are not a rejectable condition.

Rejection Criteria:

None.

Replacement Policy:

Tool stop marks are not an unacceptable manufacturing condition covered by Catalina Cylinders Return Authorization Policy.

Damage

Damage to the top surface, the o-ring gland, or the threads of a cylinder can be created during the manufacture of a cylinder and after the cylinder has been in service.

Rejection Criteria:

Damage to the top surface, the o-ring gland, or the threads of a cylinder is unacceptable if:

• it causes loss of contents of the cylinder, or
• It interrupts the required minimum number of complete threads in a cylinder

Replacement Policy:

Catalina Cylinders Return Authorization Policy covers unacceptable damage created during the manufacturing of the cylinder.

If at any time the integrity of a cylinder stamped with “CATALINA” and/or “M4002” on the crown is in question, we request you properly mark or placarded the cylinder and then contact Catalina Cylinders immediately and ask to speak with a Catalina Cylinders Return Authorization (RA) representative. Our RA office hours are Monday through Friday 8:00am – 5:00pm. Before calling, please have available the cylinder crown marking (stamping) and an explanation of your concerns about the cylinder. Having this information available at the time of the call will help expedite the resolution to your concerns. The information you provide the RA representative will determine if a RA report should be generated and the cylinder returned to Catalina Cylinders.

Catalina Cylinders recommends that anyone valving SCUBA (air) cylinders should be aware of the hazards associated with high pressure compressed air and be trained in safe practices of valving SCUBA cylinders. Catalina Cylinders has compiled the list of items below that should be included in all safe practices for the valving SCUBA (air) cylinders. For valving SCUBA cylinders to be used in oxygen enriched air service reference Catalina Cylinders technical support document, Oxygen Compatibility of SCUBA Cylinders and consult recognized authorities in oxygen enriched air.

Valve Removal

1. Verify the cylinder is free of charge and not under pressure before attempting to remove the valve.
2. Only discharge the remaining charge of a cylinder in a well ventilated area.
3. Position the cylinder with outlet port of the valve facing away from all personnel and/or equipment.
4. Slightly (“crack”) open the handwheel of the valve discharging or releasing the residual charge. Leave the handwheel of the valve open throughout the valve removal process.
5. Fitting a wrench snugly to the valve body, use force turning the wrench counter clockwise to loosen the valve.
6. If the valve cannot be loosened, stop, remove the wrench and apply a small amount of penetrating release agent at the junction of the valve and cylinder and allow time, 5 – 15 minutes, for the release agent to penetrate the junction.
7. Again attempt to loosen the valve. It may take some time to work the valve free from the cylinder. If a valve is really stuck and a release agent is used, you may have to stop periodically in the removal process and reapply the release agent and allow time for the newly applied release agent to work.
8. When a release agent is used, always clean completely the cylinder and valve of the entire release agent.

Valve Insertion

1. 1. Verify that the cylinder was manufactured for SCUBA (air) service.
   2. Verify the valve is a SCUBA valve (typically a k-type valve).
   3. Verify that the safety device is the correct safety device, is rated at the test pressure of the cylinder, and has not been actuated or altered (tampered with).
      • Never tamper with the safety device. If the safety device appears to be tampered with, do not use the valve.
      • Never replace the safety device of a valve on a cylinder that is charged.
      • If a safety device has been actuated and the cylinder has vented, then the cylinder may have been overfilled or exposed to high heat.
   4. Inspect the inlet threads and outlet port of the valve and the threads and o-ring gland of the cylinder for damage. If either the valve or cylinder has damage to the threads or the o-ring gland area, do not insert the valve into the cylinder.
   5. Inspect the cylinder threads and the cylinder internally verifying that the cylinder is free of all contaminants (i.e. release agents that may have been used to remove the valve, moisture, soils, corrosion, etc.). Do not proceed if you feel the cylinder may be contaminated. Reference Catalina Cylinders Technical Support Document, Cylinder Cleaning, for common methods of cleaning a cylinder.
   6. Catalina Cylinders recommends the insertion of a new buna-N o-ring, with a hardness of 90 shore, every time the valve of a cylinder is removed and re-installed. Verify that the new o-ring is free of all damage. Following are the buna-N o-ring sizes for the different inlet thread sizes:
      

      Thread Designation		Buna-N O-ring Size
      .750 – 16 UNF		210
      � – 14 NGS (NPSM)		214

1. 1. Catalina Cylinders has found it easiest to place the o-ring on the valve and then insert the valve into the cylinder tightening the valve hand tight. Placing the o-ring in the o-ring gland of the cylinder and then inserting the valve is known to have damaged the o-ring in some instances.
   2. Apply a small amount of lubricant, Dow Corning Compound 111, to the end of the valve and the leading 2 to 3 threads of the valve. A small amount of lubricant has been found helpful to reduce galvanic corrosion in the threads of the cylinder.
   3. Hand tightening of the valve should seat the valve completely on the cylinder (i.e. no gap between the valve and the cylinder). If there is still a gap between the valve and the bottom of the cylinder lightly tap the valve handle with a rawhide or rubber mallet to seat the valve completely. The valve should only rotate 45^o (1/8 of a turn) from the point of hand tightening to fully seated. If you decide to seat the valve using a torque wrench, following are recommended torque values by Catalina Cylinders and the CGA:
      

      Thread Designation		Catalina Cylinders Recommended Torque		Catalina Cylinders Maximum Torque
      .750 – 16 UNF		40 lbf-ft		50 lbf-ft
      � – 14 NGS (NPSM)		40 lbf-ft		50 lbf-ft

1. Close the valve with no more than 1 lbf-ft torque.